Apparatus for mounting a brake drum to a bicycle frame

ABSTRACT

An apparatus is provided for mounting a brake device to a bicycle frame, wherein the brake device brakes the hub of a wheel that rotates around a hub shaft. The apparatus comprises a fastening bracket, a bracket fastening member, and an insert member. The fastening bracket comprises a base portion adapted to receive the hub shaft therethrough; an arm portion that extends outwardly from the base portion; and a detaining portion having first and second side surfaces disposed on the arm portion for mounting the brake device to the bicycle frame. The bracket fastening member has a detaining space into which the detaining portion is inserted for detaining the fastening bracket to the bicycle frame, and the insert member has first and second contact portions that face the respective first and second side surfaces of the detaining portion when the insert member is disposed in the detaining space.

BACKGROUND OF INVENTION

[0001] The present invention is directed to bicycle brake devices and, more particularly, to bicycle brake devices that are used to brake a hub of a bicycle wheel.

[0002] Bicycle braking devices currently available include rim braking devices and hub braking devices. Rim braking devices include cantilever brakes or caliper brakes that brake the rim of the wheel. Hub braking devices brake the wheel hub, and they include drum brakes, band brakes, roller brakes and the like. A hub brake brakes the hub of the wheel, so it is able to provide braking even if the wheel rim is warped.

[0003] Conventional bicycle hub brake devices comprise a fastening bracket nonrotatably mounted to the bicycle frame, a brake drum that rotates integrally with the hub, a brake member such as a brake shoe or a brake band that provide a braking action on the brake drum, and a brake operating component for bringing the brake shoes into pressed contact with the braking surface of the brake drum.

[0004] The fastening bracket has a base section through which the hub shaft passes and that is secured to the hub shaft, an arm section that extends essentially radially from the base section, and a lock section that is formed on the distal end of the arm section. The lock section serves to mount the hub brake device to the bicycle frame, and it is mounted and secured to a bracket fastening member that is fastened to the front fork or the chainstay of the bicycle, for example.

[0005] The bracket fastening member may be of the type that is welded to the frame and serves to lock the fastening bracket in place. Alternatively, the bracket fastening member may be of the type that removably fastens the fastening bracket to the frame. If the bracket fastening member is removably fastened to the frame, a tool must be used in order to remove the bracket fastening member when mounting or removing the wheel. This is very inconvenient, especially when a quick-release hub that permits easy replacement of the wheel is used. As a result, in many cases a welded-on bracket fastening member is used to lock the fastening bracket.

[0006] A bracket fastening member that is intended to be welded to the frame is normally supplied by the brake manufacturer to the bicycle manufacturer together with the hub brake device. A locking space is formed in the center of the bracket fastening member for receiving the lock section of the fastening bracket therein to thereby lock the fastening bracket to the frame. In order to be compatible with the frame, and particularly with different orientations and configurations of the front fork, this locking space is formed such that it has an hourglass-like cross-sectional configuration in which the opening area into which the lock section is inserted and the exit area from which the lock section emerges are wider than the center area.

[0007] In the conventional mounting construction described above, a gap may exist between the lock section and the locking space when the lock section is disposed in the locking space due to erroneous mounting of the bracket securing member or the like. If a gap exists in the hub axial direction or the rotational direction, there is a danger that the hub brake device will rattle and make noise when the brake is applied.

SUMMARY OF THE INVENTION

[0008] The present invention is directed to inventive features of a bicycle braking device. In one embodiment, an apparatus is provided for mounting a brake device to a bicycle frame, wherein the brake device brakes the hub of a wheel that rotates around a hub shaft. The apparatus comprises a fastening bracket, a bracket fastening member, and an insert member. The fastening bracket comprises a base portion adapted to receive the hub shaft therethrough; an arm portion that extends outwardly from the base portion; and a detaining portion having first and second side surfaces disposed on the arm portion for mounting the brake device to the bicycle frame. The bracket fastening member has a detaining space into which the detaining portion is inserted for detaining the fastening bracket to the bicycle frame, and the insert member has first and second contact portions that face the respective first and second side surfaces of the detaining portion when the insert member is disposed in the detaining space.

[0009] Additional inventive features will become apparent from the description below, and such features alone or in combination with the above features may form the basis of further inventions as recited in the claims and their equivalents.

BRIEF DESCRIPTION OF DRAWINGS

[0010]FIG. 1 is a side view of a particular embodiment of a bicycle that includes braking components described herein;

[0011]FIG. 2 is a schematic illustration of a particular embodiment of a brake system for the bicycle;

[0012]FIG. 3 is a side view of a particular embodiment of a front brake device;

[0013]FIG. 4 is a front view of the front brake device;

[0014]FIG. 5 is a side view of the front brake device with the cover removed;

[0015]FIG. 6 is an enlarged partial cross-sectional view of the front brake device;

[0016]FIG. 7(A) is a partial cross-sectional view of a particular embodiment of a cooling disk press fit to a brake drum;

[0017]FIG. 7(B) is a partial cross-sectional view of the cooling disk crimped and caulked to the brake drum;

[0018]FIG. 8 is an exploded view of a particular embodiment of the bicycle brake device;

[0019]FIG. 9 is a perspective view of a particular embodiment of a retaining member;

[0020]FIG. 10 is a cross sectional view of the retaining member of FIG. 9 in a crimped condition;

[0021]FIG. 11 is a perspective view of another embodiment of a retaining member;

[0022]FIG. 12 is a cross sectional view of the retaining member of FIG. 11 in a crimped condition;

[0023]FIG. 13 is a perspective view of particular embodiments of an insert member and a detaining portion of a bracket body;

[0024]FIG. 14 is a side cross sectional view of the insert member and the bracket body prior to mounting the insert member;

[0025]FIG. 15 is a side cross sectional view of the insert member and the bracket body after mounting the insert member;

[0026]FIG. 16 is a side view of a particular embodiment of a brake shoe assembly;

[0027]FIG. 17 is a plan view of a portion of the brake shoe assembly;

[0028]FIG. 18 is an enlarged view of a distal end of a brake shoe;

[0029]FIG. 19 is an exploded view of a particular embodiment of mounting portions of the actuating arm;

[0030]FIG. 20 is a partial cross sectional view of the brake device in a brake released state; and

[0031]FIG. 21 is a partial cross sectional view of the brake device in a brake activated state.

DETAILED DESCRIPTION

[0032]FIG. 1 is a side view of a particular embodiment of a bicycle that includes braking components described herein. In this embodiment, the bicycle comprises a frame 1 that has a frame body 2 and a front fork 3; a handlebar portion 4 comprising a handle stem 10 fastened to the top of front fork 3 and a handlebar 11 fastened to handle stem 10 for steering; a saddle 9 for sitting; a front wheel 6; a rear wheel 7; a brake system 8 for braking front wheel 6 and rear wheel 7; and a drive section 5 for transmitting rotation of pedals 5 a to rear wheel 7.

[0033] Front wheel 6 and rear wheel 7 have front and rear hubs 6 a (FIG. 4, wherein only the front hub 6 a is shown), each having a hub spindle 15 a (FIG. 6), front and rear rims 6 b, 7 b (FIG. 1) disposed at the outside periphery of hubs 6 b, tires 6 c, 7 c attached to front and rear rims 6 b, 7 b, and spokes 6 d, 7 d connecting the hubs 6 a with the respective rims 6 b, 7 b. As shown in FIG. 6, hub 6 a hub spindle 15 a is nonrotatably mounted on front fork 3 of frame 1, and a hub shell 15 b is rotatably supported on hub spindle 15 a. Front hub 6 a has a quick release lever 6 e (FIG. 1) to provide a quick release hub that is easy to detach. The quick release mechanism is known and described, for example, in the 1993 Japanese Industrial Standard (JIS) Bicycle Edition, p. 276, published by Jitensha Sangyo Shinko Kyokai. Thus, a detailed description of the quick release mechanism will not be provided here. In this embodiment, the hubs 6 a are fastened to the front fork 3 and chain stay 2 a with an ordinary hexagon cap nut 45.

[0034] As shown in FIG. 2, brake system 8 has front and rear brake levers 12 f, 12 r, brake devices 13 f, 13 r actuated by front and rear brake levers 12 f, 12 r, and front and rear brake cables 14 f, 14 r respectively linking the front and rear brake levers 12 f, 12 r with the front and rear brake devices 13 f, 13 r. Brake cables 14 f, 14 r have inner cables 16 f, 16 r, the two ends of which are linked to front and rear brake levers 12 f, 12 r and the front and rear brake devices 13 f, 13 r. Brake cables 14 f, 14 r also have outer cables 17 f, 17 r sheathing the inner cables 16 f, 16 r. The front brake lever 12 f is mounted to the inside of a grip 18 a mounted on the left end of handlebar 11, and the rear brake lever 12 r is mounted to the inside of a grip 18 b mounted on the right end of handlebar 11. Brake levers 12 f, 12 r are identical components disposed in a mirror image relationship. Each brake lever 12 f, 12 r has a lever bracket 20 mounted on handlebar 11, a lever member 21 pivotably supported on a pivot shaft 20 a on lever bracket 20, and an outer detaining portion 22 screwed onto lever bracket 20. Each lever bracket 20 has a mounting portion 20 b and a female threaded portion 20 c, wherein mounting portion 20 b is detachably mountable to handlebar 11, and outer detaining portion 22 is threaded into female threaded portion 20 c. Inner cables 16 f, 16 r passes through their respective outer detaining portions 22 and are detained by corresponding inner detaining portions 21 a mounted to each lever member 21. Lever member 21 is biased towards the brake release position by a biasing member (not shown).

[0035] In this embodiment, the front and rear brake devices 13 f, 13 r are roller brake devices. Brake devices 13 f, 13 r function to brake the hub 6 a of front wheel 6 and rear wheel 7, respectively. As shown in FIGS. 2, 3, and 8, brake devices 13 f, 13 r have fastening brackets 30 f, 30 r for nonrotatably fastening brake devices 13 f, 13 r to the front fork 3 or chain stay 2 a of the bicycle; brake bodies 32 f, 32 r; and brake actuating portions 33 f, 33 r for actuating the brake bodies 32 f, 32 r. Each fastening bracket 30 f, 30 r has a bracket body 34 with a first face and a second face produced, for example, by press forming a sheet of steel, and a cover member 35 securely fitting onto bracket body 34 for covering the second face of bracket body 34. Cover member 35 is formed by press forming a thin metal sheet, has a baked-on finish on its surface, and has indicia such as a model number imprinted thereon. Bracket body 34 has a basal portion 34 a (FIG. 8) through which hub spindle 15 is passed, a tapering arm portion 34 b that extends substantially diametrically from basal portion 34 a, and a detaining portion 34 c formed at the distal end of arm portion 34 b with a substantially equal width plate configuration. As shown in FIG. 6, the basal portion 34 a of bracket body 34 is fastened to hub spindle 15 a by means of the hexagonal cap nut 45 screwed onto one end of hub spindle 15 a. On basal portion 34 a, except in the arm portion 34 b, is formed a tubular portion 34 d of very short length. This tubular portion 34 d forms a member mounting portion 38 comprising a pair of mounting holes 38 a, 38 b for mounting first detaining members 36, 37 that prevent the brake drum 40 from coming off in a manner described below.

[0036] As shown in FIGS. 1 and 13-15, the detaining portion 34 c of bracket body 34 is fastened to a bracket fastening member 25 f, 25 r. The detaining portion 34 c of the front bracket body 34 is detained detachably, by a one-touch operation, by bracket fastening member 25 f in order to facilitate replacement of front wheel 6. On a first face of the front detaining portion 34 c (the left face in FIG. 14), there is formed a recess 34 e recessed inwardly and extending in the mounting direction. Recess 34 e is produced by a press forming process, for example, and projects towards a second face of front detaining portion 34 c (the right face in FIG. 14). Bracket fastening member 25 f is supplied together with the front brake device 13 f by the brake manufacturer, and it is welded to the front fork 3 of the bicycle frame 1. Bracket fastening member 25 f has a detaining space 25 a for detaining portion 34 c when the latter is inserted therein. The two side walls 25 b of detaining space 25 a are bowed slightly inward so that detaining space 25 a has greater width at its mouth (the distance between the side walls 25 b at the lower end in FIG. 15) for insertion of detaining portion 34 c than it does in its medial portion situated further inward. Since the width at the mouth is greater than the width further inward, detaining portion 34 c can be detained regardless of differences in configuration of the front fork 3 of the bicycle.

[0037] An insert member 19 produced, for example, by bending a thin sheet of stainless steel for ease of manufacture, durability and corrosion resistance, is mounted on the front detaining portion 34 c. Insert member 19 is arranged such that it is situated within detaining space 25 a when mounted on detaining portion 34 c. Insert member 19 has first and second contact portions 19 a, 19 b and a third contact portion 19 c. First and second contact portions 19 a, 19 b mount onto the detaining portion 34 c from the distal edge thereof, and third contact portion 19 c contacts a side of detaining portion 34 c due to being bent out from the first contact portion 19 a which is juxtaposed to a first face of detaining portion 34 c. The first and second contact portions 19 a, 19 b are bent towards the two faces of detaining portion 34 c so that the bent portions are situated at the distal edge thereof. A convex portion 19 d is formed on first contact portion 19 a for mating with recessed portion 34 e of detaining portion 34 c. By engaging convex portion 19 d within recessed portion 34 e, insert member 19 may be mounted at a desired location on detaining portion 34 c when insert member 19 is mounted in fastening member 25 f. Since the second face of detaining portion 34 c projects outwardly (to the right in FIG. 14), the second contact portion 19 b of insert member 19 situated at this second face is bent diagonally. It is therefore easier to fill the gap of the detaining space 25 a of bracket fastening member 25 f for reducing the chatter of the brake device 13 f in the axial direction when mounted on the front fork 3. Furthermore, third contact portion 19 c is bent diagonally along detaining space 25 a as shown in FIG. 15. Accordingly, it is easy to fill in the convex gap of the detaining space 25 a of bracket fastening member 25 f for reducing chatter in the hub rotation direction.

[0038] As shown in FIGS. 2 and 3, bracket fastening members 25 f, 25 r and fastening brackets 30 f, 30 r, respectively, have mounted thereon outer mounting portions 31 f, 31 r for detaining the outer cables 17 f, 17 r. For example, outer mounting portion 31 f may be screwed to the front bracket fastening member 25 f. Outer mounting portion 31 f has an outer detaining portion 31 a and an outer fastening portion 31 b. Outer detaining portion 31 a is provided for detaining outer cable 17 f, and outer fastening portion 31 b is provided for fastening outer detaining portion 31 a in such a way that the detaining position of outer detaining portion 31 a in the cable axis direction is adjustable by means of a screw. Brake play (i.e. the gap between the brake drum and the brake shoe) can be adjusted by adjusting this axial position. Since outer mounting portions 31 f are mounted to the frame, there is no need to attach or detach the outer cable when attaching or detaching the wheel.

[0039] Since brake bodies 32 f, 32 r are of substantially identical structure, only the front brake body 32 f will be described. As shown in FIG. 6, front brake body 32 f has a brake drum 40 and a brake shoe 41. Brake drum 40 has a cylindrical drum body 43 that rotates integrally with the hub shell 15 b through a left pocket 15 c. Drum body 43 is a stainless steel alloy member having a bowl configuration with a bottom portion 50 and a peripheral portion 51 formed at the outside periphery of bottom portion 50. A contoured (splined) portion 50 b is formed on the inside peripheral surface of an opening 50 a in bottom portion 50, wherein the splined portion 50 b meshes with a complementary splined portion formed on the outer peripheral surface of left pocket 15 c. As a result, drum body 43 is nonrotatably mounted relative to hub shell 15 b.

[0040] A circular brake face 51 a is formed on the inside peripheral face of peripheral portion 51, wherein brake shoe 41 is capable of contacting with and releasing from brake face 51 a to provide a braking force to brake drum 40. Brake face 51 a is produced by recessing the axial center portion of peripheral portion 51 in an isosceles trapezoidal shape whose cross section constricts in width going outwardly in the diametrical direction. As shown in FIGS. 7(A) and 7(B), the angle Î± at which the two sides of brake face 51 a intersect ranges from 15Â° to 150Â°, preferably 80Â° to 100Â°. Brake face 51 a has a diametrically outwardly extending annular grease filled recess 54 packed with grease. Grease filled recess 54 has a first groove 54 a, formed in the most deeply recessed portion of brake face 51 a so that grease tends to flow into first groove 54 a through centrifugal force during riding, and a pair of second grooves 54 b situated on brake face 51 a at opposite sides of first groove 54 a to increase the amount of grease that may be supplied. Grease filled recess 54 is packed with grease at the time of assembly.

[0041] A cooling disk 44 made of aluminum alloy is thermally coupled to the outer peripheral surface of drum body 43. Cooling disk 44 has a tubular portion 44 b and a disk portion 44 c, wherein disk portion 44 c extends diametrically outward from tubular portion 44 b. A plurality of radially extending cooling fins 44 a (FIG. 4) are formed on the inside (right side) face of cooling disk 44 for dissipating heat from hub body 43. Such dissipation is enhanced by the increased surface area as well as the increased contact with air when the wheel is spinning.

[0042] As shown in FIGS. 7(A)and 7(B), a knurled portion 51 b is formed on the outside peripheral face of peripheral portion 51 by means of a knurling process in order to prevent rotation of cooling disk 44 relative to hub body 43 when cooling disk 44 is mounted to hub body 43. The outer peripheral surface of peripheral portion 51 also has formed thereon a first tapered face 51 c and a second tapered face 51 d situated on opposite sides of knurled portion 51 b, wherein tapered faces 51 c, 51 d taper downwardly in the diametrical direction. First tapered face 51 c is provided for axially detaining the cooling disk 44 to drum body 43, and second tapered face 51 d is provided for fastening cooling disk 44 to hub body 43 by crimping and/or caulking. A flat outer peripheral press fitting face 51 e is formed between first tapered face 51 c and knurled portion 51 b. Cooling disk 44 is press fit onto the entire circumference of press fitting face 51 e and the knurled portion 51 b so that grease packed into the brake drum 40 can be prevented from flowing through the side of hub 6 a.

[0043] During the fabrication stage, a cylindrical caulk fastening portion 44 d is formed on a first end of tubular portion 44 b (the right end in FIG. 7(A)). To fasten the cooling disk 44 to the drum body 43 during the assembly stage, the tubular portion 44 b is initially press fit onto the outside peripheral face of drum body 43 as shown in FIG. 7(A). A shaving reservoir portion 58 is formed on the inside peripheral surface of tubular portion 44 b for holding shavings produced by knurled portion 51 b during the press fitting process. Thereafter the caulk fastening portion 44 d is bent diametrically inward towards the second tapered face 51 d of the drum body 43 as shown in FIG. 7(B) using a roller or some other suitable jig. By press fitting the cooling disk 44 and caulking it onto the drum body 43 in this manner, the cooling disk 44 is securely fastened onto the drum body 43, especially in the axial direction. The larger contact area produced by the tapered faces also improves cooling efficiency. The press fitting/caulking operation does not require application of heat, and it can be performed at the same location. Thus, heat-induced discoloration and deformation is avoided, the labor entailed in the production process is reduced, and the cooling disk 44 is fastened to the drum body 43 in a simple and inexpensive manner.

[0044] The other end of the tubular portion 44 b of cooling disk 44 (the left end in FIG. 7) has a diametrically outwardly projecting annular convex portion 44 e for preventing the brake drum 40 from coming off of the fastening bracket 30 when attaching or detaching the brake device 13 f. More specifically, two kinds of first retaining members 36, 37 (FIGS. 8-12) are detachably mounted on member mounting portion 38 of tubular portion 34 d of bracket body 34, and a second retaining member 39 is produced by bending cover member 35 diametrically inwardly. First retaining members 36, 37 and second retaining portion 39 are received in the annular groove formed between annular convex portion 44 e and disk portion 44 c of cooling disk 44

[0045] As shown in FIGS. 9 and 10, first retaining member 36 is a bent plate member made of stainless steel alloy. First retaining member 36 has a retaining projection 36 a that is adapted to be fitted axially inwardly of annular convex portion 44 e, a mounting portion 36 b produced by bending retaining projection 36 a so as to be situated against the inner peripheral face of tubular portion 34 d, and bent fastening portions 36 c produced by cutting the two ends of mounting portion 36 b and bending them in the upward direction as shown in FIG. 9. These bent fastening portions 36 c are inserted into mounting holes 38 a, 38 b from the inner peripheral side of tubular portion 34 d, and their distal ends are bent over to mount the first retaining member 36 onto the inside peripheral face of tubular portion 34 d as shown in FIG. 10.

[0046] As shown in FIGS. 11 and 12, first retaining member 37 is a bent plate member made of stainless steel alloy. First retaining member 37 has retaining projection 37 a that is adapted to be fitted axially inwardly of annular convex portion 44 e of cooling disk 44 a mounting portion 37 b produced by bending retaining projection 37 a so as to be situated against the outer peripheral face of tubular portion 34 d, and elastic fastening portions 37 c produced by cutting the two ends of mounting portion 37 b and bending them in the downward direction in a U-shape as shown in FIG. 11. These elastic fastening portions 37 c are inserted into mounting holes 38 a, 38 b from the outside peripheral side of tubular portion 34 d. Once elastic fastening portions 37 c have passed through mounting holes 38 a, 38 b, they spread out due to elasticity and are elastically detained on tubular portion 34 d, thereby fastening the first retaining member 37 to the outside peripheral face of tubular portion 3. Although the tips of the elastic fastening portions 37 c are shown touching the inner peripheral surface of tubular portion 34 d, they may instead touch the side walls of mounting holes 38 a, 38 b. 4 d. First retaining member 37 may be removed by prying mounting portion 37 b.

[0047] As shown in FIG. 8, the second retaining member 39 is formed by bending the cover member 35 inwardly. Second retaining member 39 also is provided for preventing the brake drum 40 from coming off, as well as to detain the cover member 35 on the bracket body 34. Cover member 35 is fastened to tubular portion 34 d by means of elastic detenting. Providing a second retaining member 39 on cover member 35 allows the number of retaining members 36, 37 to be reduced as well as reducing manufacturing costs and the number of steps required to attach the bracket body 34 to brake drum 40. Cover member 35 has a bulging portion 35 a formed so as to cover the outside peripheral side of first retaining portion 37, thus making the first retaining member 37 (which is easier to detach than the first retaining member 36 because the first retaining member 36 was fastened to tubular portion 34 d by bending) harder to remove.

[0048] By preventing the brake drum 40 from coming off by means of first retaining members 36, 37, which are detachable from the tubular portion 34 d, and the second retaining member formed on cover member 35 r, damage to fastening bracket and cover member 3530 f is prevented when first retaining members 36, 37 and second retaining member 39 are attached or detached. The brake drum 40 thus can be retained without breaking fastening bracket and cover member 35 30 f, when brake device 13 r is repeatedly disassembled and reassembled.

[0049] In this embodiment, as shown in FIGS. 16 and 17, brake shoe 41 consists of a ring-shaped member divided into three segments in the circumferential direction. A contact face 41 a is formed on the outer peripheral surface of each segment of brake shoe 41 for contacting the brake face 51 a of drum body 43 during braking. Each contact face 41 a has a cross sectional shape in the form of an isosceles trapezoid projecting convexly in the radially outward direction so as to contact brake face 51 a. The angle 12 of intersection of the two sides of contact face 41 a is equal to or greater than the intersect angle Î± of brake face 51 a. As shown in FIG. 18, sloping faces 41 e are formed at the two end portions of the contact faces 41 a such that an acute angle Î³ is formed with respect to a tangent line 81 at the location of contact of a sloping face 41 e with an arbitrary arc 80 on brake face 51 a. By providing such sloping faces 41 e, grease delivered to the sloping faces during rotation of the brake drum 40 can be supplied smoothly to the brake face 51 a. Thus, grease depletion is not likely to occur at the brake face 51 a. In the center of contact face 41 a is formed an annular housing recess 41 b in which a first spring member 53 is mounted. Housing recess 41 b is formed so as to be juxtaposed to first groove 54 a of grease filled recess 54 in drum body 43.

[0050] Three diametrically outwardly recessed rotation stop portions 41 c extending a predetermined length in the rotation direction is formed on the inside peripheral surface of brake shoe 41. Three detaining projections 34 f (FIGS. 6 and 8) formed on bracket body 34 of fastening bracket 30 f fit within these rotation stop portions 41 c, thus preventing rotation of the segmented brake shoe 41 relative to bracket body 34. Of course, brake shoe 41 will rotate slightly due to play between detaining projections 34 f and rotation stop portions 41 c.

[0051] The first spring member 53 mounted in housing recess 41 b is an annular spring member formed by bending elastic wire material into a circle. Such a configuration makes it easy to bias each segment of brake shoe 41 inwardly towards a position away from the brake drum 40 (i.e., diametrically inward). A first end of the first spring member 53 has a projecting portion 53 a that is bent to project diametrically outwardly. In this embodiment, projecting portion 53 a projects outwardly approximately 0.4 mm-2.0 mm from the inside peripheral portion. As a result, when brake shoe 41 contacts the brake drum 40 during braking, the distal end of projecting portion 53 a tends to be situated within first groove 54 a of grease filled recess 54. During brake release, when the brake shoe 41 comes away from the brake drum 40, projecting portion 53 a tends to be situated diametrically inward from first groove 54 a groove. In this way, during braking (and possibly only during braking), projecting portion 53 a can rake out the grease packed into first groove 54 a towards the brake face 51 a. The size of projecting portion 53 a also ends to require no major change in the usual assembly machinery, assembly process, tools, or the like.

[0052] Brake actuating portions 33 f, 33 r are substantially identical in construction despite their difference in shape, so only the front brake actuating portion 33 f will be described here. The front brake actuating portion 33 f is rotatably disposed on fastening bracket 30, and it is used to push the segments of brake shoe 41 towards the brake drum 40. As shown in FIGS. 8 and 19, the front brake actuating portion 33 f has an actuating arm 60 adapted to be mounted on the bracket body 34 of fastening bracket 30 f so that actuating arm 60 rotates round the hub spindle 15 a; a cam member 61 that rotates in unison with the actuating arm 60; a plurality of rollers 62 (e.g., six) disposed between and contacting cam member 61 and brake shoe 41; and a roller case 63 for holding the rollers 62 spaced apart from each other in the rotation direction.

[0053] Actuating arm 60 is fabricated from a metal plate. An inner mounting portion 64 is detachably mounted to the distal end of actuating arm 60 for detaining the distal end of inner cable 16 f of brake cable 14 f. Actuating arm 60, which is actuated by means of inner cable 16 f via inner mounting portion 64, is linked to the brake lever 12 f mounted on the handlebar portion 4 of the bicycle. The basal end of actuating arm 60 is bent and has a mating hole 60 a (FIG. 8) for mating with the outside peripheral face of cam portion 61. Actuating arm 60 rotates between a brake released position (shown in FIG. 20) and a braking position (shown in FIG. 21) Actuating arm 60 is biased toward the brake released position by a second spring member 70 in the form of a torsion coil spring. One end of spring member 70 is detained by bracket body 34, and the other end of spring member 70 is detained in a detaining hole 60 b formed in the distal end of actuating arm 60. Second spring member 70 is covered by cover member 35.

[0054] As shown in FIG. 19, a mounting slot 65 is formed on the distal end of actuating arm 60 for detachably mounting the inner mounting portion 64. Mounting slot 65 proceeds up from the bottom of the distal end of actuating arm 60, bends towards the rotational axis of the actuating arm 60, and then bends diagonally downward. Slot 65 includes a constricted portion 65 a that is disposed at the bent portion, wherein constricted portion 65 a is narrower in width than other portions. In this embodiment, constricted portion 65 a has a width d2 of 5.4 mm, and a back end/front end width d1 of 5.9 mm. An attachment/detachment operation portion 60 c used for attaching or detaching inner mounting portion 64 is formed at the bottom of the distal end of actuating arm 60. Attachment/detachment operation portion 60 c also facilitates rotation of actuating arm 60, of necessary, when attaching and detaching inner mounting portion 64 from actuating arm 60.

[0055] Inner mounting portion 64 has a plate-shaped arm body 66 formed by bending metal sheet material, a retaining portion 67 disposed at the basal end of arm body 66 (the bottom end in FIG. 19), and a cable detaining portion 68 screwed to the distal end of arm body 66. The basal end of arm body 66 is bent into a “U” configuration to form a bracket portion 66 a for supporting retaining portion 67. Retaining portion 67 is detachably and rotatably mounted in mounting slot 65 of actuating arm 60, and cable detaining portion 68 is provided for detaining inner cable 16 f. An attachment/detachment operation portion 66 b that aligns with cable detaining portion 68 is formed at the distal end of arm body 66. Attachment/detachment operation portion 66 b extends away from cable detaining portion 68 and then bends sideways. Inner cable 16 f thus may be removed as a unit with inner mounting portion 64, and it is not necessary to adjust the brake play every time the wheel is replaced. Also, since inner mounting portion 64 is a large member, it may be easily removed with one hand.

[0056] Retaining portion 67 has a flanged retaining shaft 67 a fixed to bracket portion 66 a, a spring pin 67 b mounted on retaining shaft 67 a, and a washer 67 c disposed such that it contacts spring pin 67 b. Spring pin 67 b has an axially extending slit formed in its outside periphery, and it may be formed by winding elastic sheet material. Spring pin 67 b has an outside diameter greater than constricted portion 65 a of mounting slot 65, a width smaller than mounting slot 65 with the exception of constricted portion 65 a, and an inside diameter greater than the outside diameter of retaining shaft 67. When spring pin 67 b is inserted into the mounting slot 65 to mount the inner mounting portion 64 on actuating arm 60, spring pin 67 b inserts smoothly into the entrance of mounting slot 65, is diametrically constricted as it passes through the constricted portion 65 a of mounting slot 65, and then expands to its original shape once it has passed through the constricted portion 65 a. As a result, it will not return back through the constricted portion 65 a during normal operation. However, when holding the two attachment/detachment operation portions 60 c, 66 b, the retaining portion 67 moves easily out of the mounting slot, and the inner mounting portion 64 can be easily detached from the actuating arm 60.

[0057] Cam member 61 is nonrotatably fixed to actuating arm 60 so that it rotates in response to rotation of actuating arm 60. As shown in FIGS. 8, 20 and 21, cam member 61 may be a thick-walled tubular member fabricated of steel. A plurality of cam portions 61 c are formed on the outer peripheral face of cam member 61. Each cam portion 61 c has a sloping cam face 61 a and a recessed portion 61 b. In this embodiment, the distance in the diametrical direction of each cam face 61 a increases gradually in the clockwise direction in FIG. 20, and the recessed portions 61 b are recessed below adjacent pairs of sloping cam faces 61 a.

[0058] Roller abutting faces 41 d (FIG. 16) that project diametrically inwardly are disposed at the inside peripheral surface at the two ends of each segment of brake shoe 41. Rollers 62 are mounted between the outside peripheral surface of cam member 61 and the roller abutting face 41 d of brake shoe 41. Rollers 62 are used to push against brake shoe 41 in response to rotation of cam member 61. Rollers 62 are mounted in a roller case 63 in such a manner that they are spaced apart in a circumferential direction while being capable of movement in a diametrical direction in response to rotation of cam member 61. More specifically, a plurality of retaining projections 63 a (e.g., six) are formed in roller case 63. The retaining projections 63 a are circumferentially spaced apart and project outwardly in the hub axial direction for retaining the rollers 62. Roller case 63 is nonrotatably detained to bracket body 34 by means of a retaining projection 63 b that projects axially further than the other retaining projections 63 a. As shown in FIGS. 5, 6, and 8, a slot 34 g that is elongated in the rotation direction is formed in bracket body 34 for mating with this retaining projection 63 b. A third spring member 72 is mounted between retaining projection 63 b and bracket body 34 for biasing the roller case 63 in the clockwise direction in FIG. 20. Thus, the rollers 62 are substantially fixed relative to bracket body 34. Grease is packed within the roller case 63 around the rollers 62 in the same manner as for brake face 51 a so that rollers 62 can move smoothly in the diametrical direction in response to rotation of cam member 61. The use of rollers also helps to minimize evaporation of grease and the fluctuation in braking performance due to a rise in brake temperature.

[0059] The operation of brake devices 13 f, 13 r will be described with reference to the front brake device 13 f described above. With the brake cables 14 f, 14 r set up, the inner cables 16 f, 16 r are under tension, and play between brake shoe 41 and brake drum 40 in the absence of operation of brake levers 12 f, 12 r may be adjusted by means of the outer detaining portion 22 mounted on brake levers 12 f, 12 r or the outer mounting portions 31 f, 31 r mounted on brake device 13 f, 13 r. In this state, squeezing the front brake lever 12 f causes the inner cable 16 f to pull in opposition to the biasing force of the second spring member 70, so that the actuating arm 60 rotates from the brake release position shown in FIG. 20 to the braking position shown in FIG. 21.

[0060] When actuating arm 60 rotates to the braking position, cam member 61 rotates integrally therewith, and the rollers 62 ride up over the sloped cam faces 61 a. As a result, rollers 62 are displaced diametrically outwardly and press the contact faces 41 a of brake shoe 41 against the brake face 51 a of brake drum 40 in opposition to the biasing force of the first spring member 53. This initially produces a braking force proportional to the pushing force on brake shoe 41. Since brake drum 40 is rotating in the counterclockwise direction of FIG. 21 at this time, brake shoe 41 also turns slightly counterclockwise, and roller case 63 rotates slightly in the same direction via rollers 62. This causes rollers 62 to be displaced further diametrically outwardly and produces an increased braking force. Since the brake face 51 a is recessed in a trapezoidal configuration and the contact face 41 a projects outwardly in a trapezoidal configuration, the frictional contact force between the friction faces increases through a wedging action. Since the contact area is larger than it would be between flat peripheral surfaces, the frictional force is larger and produces a high braking torque in a unit of compact size. On the other hand, the heat generated per unit of surface area is held to a lower level. Thus, high brake temperature is unlikely to occur, and a fluctuation in braking force due to a rise in brake temperature can be reduced.

[0061] When the hand is released from front brake lever 12 f, actuating arm 60 returns to the brake released position in accordance with the biasing force of the second spring member 70. Since cam member 61 rotates integrally with actuating arm 60, rollers 62 ride down the sloped cam faces 61 a, and the brake shoe 41 moves diametrically inwardly in accordance with the biasing force of the first spring member 53. At this time, the roller case 63 rotates in the clockwise direction in accordance with the biasing force of the third spring member 72, and the braking force stops.

[0062] When assembling the brake drum 40, the drum body 43 and cooling disk 44 forms are fabricated by a process such as die casting or forging, and the forms are then finished to the desired dimensions by machining processes. At that time, cooling disk 44 has a shape like that shown in FIG. 7(a), with caulk fastening portion 44 d having the form of a cylinder. Cooling disk 44 then is press fit onto the outside peripheral surface of drum body 43. After being press fit, caulk fastening portion 44 d is bent diametrically inward towards the caulking face 51 d to effect caulking of the cooling disk 44 to the drum body 43 using a roller or the like.

[0063] Then, two segments of the brake shoes 41 and the first spring member 53 are assembled and mounted inside the drum body, and the remaining segment of brake shoe 41 is attached so that the first spring member 53 enters the housing recess 41 b. The interior may be packed with ample grease at this time. When the mounting of brake shoe 41 is completed, the segments of brake shoe 41 are pushed against brake face 51 a, the rollers 62 are mounted in the roller case 63, and both are inserted diametrically inwardly of brake shoe 41. The interior may be further coated with ample grease at this time.

[0064] Then, the cam member 61 having the actuating arm 60 fastened thereto is inserted diametrically inwardly of rollers Retaining member 36 is attached to tubular portion 34 d of bracket body 34, bracket body 34 is assembled to brake drum 40 so that retaining member 36 engages annular protrusion 44 e on brake drum 40, and retaining member 37 is attached to tubular portion 34 d of bracket body 34 from the outside to engage annular protrusion 44 e. The two kinds of retaining members 36, 37 thus prevent brake drum 40 from coming off. Finally, the third spring member 72 is hooked between bracket body 34 and detaining projection 63 b of roller case 63, and the cover member 35 is attached to complete the assembly procedure. The disassembly procedure is the reverse of the above. Thus, fastening bracket 30 f and brake drum 40 may be removed as a unit from the frame, and then brake drum 40 may be removed from fastening bracket 30 f by removing cover 35, prying retaining member 37 from tubular portion 34 d of bracket body 34, and tilting bracket body 34 to disengage retaining member 36 from the annular protrusion 44 e of brake drum 40.ove.

[0065] When assembling the front wheel 6 having the brake device 13 f mounted thereon onto the front fork 3, the insert member 19 mounted on the detaining portion 34 c of bracket body 34 of brake device 13 f is pushed into bracket fastening portion 25 f, and the hub spindle 15 a of hub 6 a is mounted on front fork 3. The hexagonal cap nuts 45 are then installed on both ends of hub spindle 15 a and tightened to the appropriate level of torque to complete mounting of the front wheel 6. Once the front wheel 6 has been mounted, the inner mounting portion 64 is mounted on the actuating arm 60 by inserting the spring pin 67 b into mounting slot 65.

[0066] The front wheel 6 may be removed by substantially reversing the above procedure. However, when removing the inner mounting portion 64, the attachment/detachment operation portion 60 c is held with one hand, the attachment/detachment portion 66 b is held with the other hand, and the retaining portion 67 of the inner mounting portion 64 is withdrawn from the mounting slot 65. At this time, a small amount of force is needed to constrict the diameter of the spring pin 67 b as it passes through the constricted portion 65 a, but the part removes easily once past the constricted portion. Since the inner mounting portion 64 is not a small part, unlike conventional ones, it is easily grasped and easy to attach and detach.

[0067] While the above is a description of various embodiments of inventive features, further modifications may be employed without departing from the spirit and scope of the present invention. For example, a roller brake for braking the wheel hub was described, but the hub brake device is not limited thereto. The inventive features may be applied to a band brake or drum brake for braking the hub. The brake face 51 a and contact face 41 a in the described embodiment have a trapezoidal configuration, but the brake face 51 a and contact face 41 could be flat faces instead. While the insertion member 19 in the described embodiment was formed form a metal sheet, the insertion member may be easily molded from a hard synthetic resin. The method for crimping and/or caulking the cooling disk 44 is not limited to that described in the preceding embodiment. In the above embodiment, a cooling disc was provided with an annular protrusion formed thereon, but the outer peripheral surface of the drum main unit could have the annular protrusion if no cooling disc is provided. Also, while the retaining members 36, 37 were bent and fixed or based on elastic engagement, the method for fixing the first detents is not limited to these options. An alternative method such as screwing can also could be used. A second detent was provided on the cover member 35 in the described embodiment, but the second detent may also be provided on the bracket main unit 34.

[0068] The size, shape, location or orientation of the various components may be changed as desired. Components that are shown directly connected or contacting each other may have intermediate structures disposed between them. The functions of one element may be performed by two, and vice versa. The structures and functions of one embodiment may be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the scope of the invention should not be limited by the specific structures disclosed or the apparent initial focus or emphasis on a particular structure or feature. 

1. An apparatus for mounting a brake device to a bicycle frame, wherein the brake device brakes the hub of a wheel that rotates around a hub shaft, and wherein the apparatus comprises: a fastening bracket comprising: a base portion adapted to receive the hub shaft therethrough; an arm portion that extends outwardly from the base portion; and a detaining portion having first and second side surfaces disposed on the arm portion for mounting the brake device to the bicycle frame; a bracket fastening member having a detaining space into which the detaining portion is inserted for detaining the fastening bracket to the bicycle frame; and an insert member comprising first and second contact portions that face the respective first and second side surfaces of the detaining portion when the insert member is disposed in the detaining space.
 2. The apparatus according to claim 1 wherein the insert member is a metal plate.
 3. The apparatus according to claim 2 wherein the insert member comprises a synthetic resin.
 4. The apparatus according to claim 1 wherein the insert member comprises a bent plate that is bent to form the first and second contact portions such that the insert member straddles a distal end of the detaining portion.
 5. The apparatus according to claim 4 wherein the insert member comprises a stainless steel plate.
 6. The apparatus according to claim 1 wherein the detaining portion has a recess formed on the first side surface and a protrusion formed on the second side surface, wherein the first contact portion of the insert member has a convex surface that engages the recess, and wherein the second contact portion engages the protrusion.
 7. The apparatus according to claim 6 wherein the detaining portion has a plate shape.
 8. The apparatus according to claim 6 wherein the recess extends from the first side surface toward the second side surface such that the recess extends toward the protrusion.
 9. The apparatus according to claim 1 wherein an opening of the detaining space into which the detaining portion is inserted is wider than an interior portion of the detaining space.
 10. The apparatus according to claim 9 wherein the insert member further comprises a third contact portion that extends from at least one of the first and second contact portions and faces a third side surface of the detaining portion when the insert member is disposed in the detaining space.
 11. The apparatus according to claim 10 wherein the third contact portion is shaped to follow the contour of the detaining space.
 12. The apparatus according to claim 1 wherein at least one of the first and second contact portions of the insert member is angled away from its corresponding first and second side surface of the detaining portion.
 13. The apparatus according to claim 12 wherein the detaining portion has a recess formed on the first side surface and a protrusion formed on the second side surface, wherein the first contact portion of the insert member has a convex surface that engages the recess, and wherein the protrusion angles the second contact portion of the insert member away from the second side surface of the detaining portion.
 14. The apparatus according to claim 13 wherein an opening of the detaining space into which the detaining portion is inserted is wider than an interior portion of the detaining space.
 15. The apparatus according to claim 14 wherein the insert member further comprises a third contact portion that extends from at least one of the first and second contact portions and faces a third side surface of the detaining portion when the insert member is disposed in the detaining space.
 16. The apparatus according to claim 15 wherein the third contact portion is shaped to follow the contour of the detaining space.
 17. The apparatus according to claim 16 wherein the insert member comprises a bent plate that is bent to form the first and second contact portions such that the insert member straddles a distal end of the detaining portion.
 18. The apparatus according to claim 17 wherein the detaining portion has a plate shape. 